CHAPTER 1

INTRODUCTION

1.1. Introduction to Five-Speed Manual Gearbox

When a vehicle is starting from rest, accelerating, hill climbing and meeting
other resistances, a high tractive effort is required at the driving wheels. The tractive
effort at the wheels is dependent upon the torque developed by the engine. To enable
the engine to increase torque to drive line, a torque multiplier (transmission) is
required. By using transmission (gearbox), it is possible to adapt the available power
of the engine to meet changing road and load conditions.
The gearbox has the capability to enable the engine turning effect and its
rotational speed output to be adjusted by choosing a range of under and overdrive gear
ratios. So the vehicle responds to the driver’s requirements within the limits of the
various road conditions. The purposes of gearbox are:
1. To increase the turning effort (torque) applied to the driving wheels.
2. To enable the engine to operate within a given range of speed irrespective
of the vehicle speed.
3. To give reverse motion of the vehicle.
4. To provide a neutral position.
There are two types of gearbox, manual and automatic. Both do the same job.
If the car has a manual gearbox, the driver moves the shift lever to shift gears.
Automatic gearbox does the job automatically without any effort by the driver.
Manual transmission consists of a casing iron or aluminum housing, shafts, bearings,
gears, synchronizing devices and shifting mechanisms. Automatic transmission
includes a torque converter, compound planetary gear set, two or more disc clutches
and one or more bands. Automatic gearbox is better than manual gearbox. But manual
gearbox is used for many cars in various models and locations.
The necessary conditions for Automotive Gearbox are:
1. Be economical and highly efficient.
2. Allow easy, accurate and quiet operation.
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3. Be easily operated and serviced, light in weight and compact in design.

4. Transmit power smoothly and accurately.
The transmission may mount to the clutch housing or may be an integral part
of the differential housing (transaxle design). In Front engine rear wheel drive
vehicles, the gearbox is located between clutch and drive shaft. In front wheel drive
vehicles, the gearbox is located between clutch and differential in transaxle. Gear or
drive ratios vary, depending on car weight, engine power, etc.
Today, automotive vehicles are widely used in many countries for
transportation and other purposes. Automotive technology is also a required sector to
develop the country rapidly. In Myanmar, professional automobile production has
been manufactured in Myanmar Industrial Zones, which are trained under the leading
of Ministry of Industry (2). Mazda Jeeps and Hino Trucks have been produced in
Ministry of Industry (2) since 1970s.

Fig.1.1. OKKALA Jeep

Now, OKKALA Jeep as shown in Fig.1.1. Light Truck (1 ton) and Truck (2
ton) are also produced from South OKKALA Industrial Zone. This industrial zone
can be produced 30 jeeps per year. OKKALA Jeep vehicle is front engine rear wheel
drive vehicle. In this jeep vehicle, 2C engine and its gearbox are installed. This
gearbox is a manual five speed transmission. That is, it has five forward speeds and
one reverse. Fifth speed is actually overdrive. All forward gears are synchronized.
This gearbox consists of the six gear assembly trains, four shafts which include input,
counter, output and idler and bearings. In this thesis, the design analysis of OKA-05
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five speed manual gearbox is described. Fig.1.2. shows the assembly of five speed
manual gearbox.

Fig.1.2. Assembly of Five Speed Manual Transmission

1.2. Aim and Objectives of the Thesis

The main aim of this thesis deals with the design and analysis of five speed
manual transmission for OKA-05 Jeep. The objectives of this thesis are:
1. To study the general design consideration of five speed manual gearbox.
2. To study the operation system of vehicle transmission
3. To calculate gears design.
4. To calculate shafts design.
5. To select bearings for three main shafts.

1.3. Scope of the Thesis

In this thesis, operation and main components of transmission system for
OKA-05 Jeep is discussed. In this jeep, the engine which has the power rating 61 kW
and 4200 rpm is used. The gear box has five forward speeds and one reverse which is
driven by manual. In this thesis, design calculation of gears, shafts and bearings
selection are presented.

1.4. Implementation Program of the Thesis

The implementation program of this thesis is carried out by the following
procedures:
1. Studying the transmission system of OKA-05 Jeep.
2. Studying the type, components and material choices of gearbox.
3. Collecting the required data for the design calculation.
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4. Calculating the design of gears and shafts.

5. Selecting the bearings for three main shafts.
1.5. Outline of the Thesis
This thesis comprises of five chapters. At first, introduction is expressed.
Chapter two involves the literature reviews of gearbox. And then, chapter three
consists of the design consideration of gearbox which involves spur and helical gear
design, shaft design and bearing selection. The design calculation of gears, shafts and
selection of bearing are expressed in chapter four. Finally, conclusion, discussions and
recommendations are described in chapter five.